A three dimensional finite element study of the flat strip rolling process.

Abstract

Several analytical models were developed to study the flat strip rolling process; most of them were based on the force equilibrium or slab method, slip line field and upper bound techniques. This chapter analyzes the flat strip rolling process using a three-dimensional elastic plastic, large strain finite element formulation with accurate account of contact between the roll and the strip, and roll flattening. This model is based on an elastic-plastic large strain theory with full account of the contact frictional conditions, and overcomes the drawback of the rigid plastic approach. The results of the 3D model are compared with those of the conventional plane strain model. The stress and the strain histories obtained from the 3D model in the deformation zone are used in a workability limit analysis to check against potential edge cracks in this process. It has been found that the use of a higher reduction percent, the presence of over-cambering as well as the presence of large aspect ratio all enhance the conditions leading to edge cracking.